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. 2023 May 21;16(10):3872.
doi: 10.3390/ma16103872.

Development and Characterization of Thermoformed Bilayer Trays of Paper and Renewable Succinic Acid Derived Biopolyester Blends and Their Application to Preserve Fresh Pasta

Eva Hernández-García  1 , Marta Pacheco-Romeralo  1 , Pedro Zomeño  2 , Gianluca Viscusi  3 , Francesca Malvano  3 , Giuliana Gorrasi  3 , Sergio Torres-Giner  1
Affiliations

Development and Characterization of Thermoformed Bilayer Trays of Paper and Renewable Succinic Acid Derived Biopolyester Blends and Their Application to Preserve Fresh Pasta

Eva Hernández-García et al. Materials (Basel). .

Abstract

The present study reports on the development by thermoforming of highly sustainable trays based on a bilayer structure composed of paper substrate and a film made of a blend of partially bio-based poly(butylene succinate) (PBS) and poly(butylene succinate-co-adipate) (PBSA). The incorporation of the renewable succinic acid derived biopolyester blend film slightly improved the thermal resistance and tensile strength of paper, whereas its flexural ductility and puncture resistance were notably enhanced. Furthermore, in terms of barrier properties, the incorporation of this biopolymer blend film reduced the water and aroma vapor permeances of paper by two orders of magnitude, while it endowed the paper structure with intermediate oxygen barrier properties. The resultant thermoformed bilayer trays were, thereafter, originally applied to preserve non-thermally treated Italian artisanal fresh pasta, "fusilli calabresi" type, which was stored under refrigeration conditions for 3 weeks. Shelf-life evaluation showed that the application of the PBS-PBSA film on the paper substrate delayed color changes and mold growth for 1 week, as well as reduced drying of fresh pasta, resulting in acceptable physicochemical quality parameters within 9 days of storage. Lastly, overall migration studies performed with two food simulants demonstrated that the newly developed paper/PBS-PBSA trays are safe since these successfully comply with current legislation on plastic materials and articles intended to come into contact with food.

Keywords: biopolymers; food preservation; migration; paper; thermoforming.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
(a) Vacuum thermoformer; (b) mold chamber; (c) trays of paper, paper/polyethylene terephthalate (PET), and paper/poly(butylene succinate) (PBS) and poly(butylene succinate-co-adipate) (PBSA).
Figure 2
Figure 2
(a) As-received fresh pasta. Fresh pasta packaged in trays of: (b) uncoated paper, (c) paper/poly(butylene succinate) (PBS) and poly(butylene succinate-co-adipate) (PBSA), and (d) paper/polyethylene terephthalate (PET).
Figure 3
Figure 3
Spectral distribution curves of the percentage internal transmittance (Ti) of the paper sheet, poly(butylene succinate) and poly(butylene succinate-co-adipate) (PBS–PBSA) blend and polyethylene terephthalate (PET) films, and paper/PBS–PBSA and paper/PET trays.
Figure 4
Figure 4
Field-emission electron microscopy (FESEM) micrographs taken at the cross-section of the poly(butylene succinate) and poly(butylene succinate-co-adipate) (PBS–PBSA) blend film (a), polyethylene terephthalate (PET) film (b), paper sheet (c), paper/PBS–PBSA tray (d), and paper/PET tray (e).
Figure 5
Figure 5
Thermogravimetric analysis (TGA) curves of the paper sheet, poly(butylene succinate) and poly(butylene succinate-co-adipate) (PBS–PBSA) blend and polyethylene terephthalate (PET) films, and paper/PBS–PBSA and paper/PET trays.
Figure 6
Figure 6
Typical tensile stress (σ) vs. deformation (ε) curves of the paper sheet, poly(butylene succinate) and poly(butylene succinate-co-adipate) (PBS–PBSA) blend and polyethylene terephthalate (PET) films, and paper/PBS–PBSA and paper/PET trays: (a) prior to storage; (b) after 21 days of storage at 5 °C and 85% relative humidity (RH).
Figure 7
Figure 7
(a) Typical flexural stress (σ) vs. deformation (ε) curves and (b) force (F) vs. displacement (d) during the puncture process of the paper sheet, poly(butylene succinate) and poly(butylene succinate-co-adipate) (PBS–PBSA) blend and polyethylene terephthalate (PET) films, and paper/PBS–PBSA and paper/PET trays.
Figure 8
Figure 8
Typical force vs. distance curves of the paper/poly(butylene succinate) (PBS) and poly(butylene succinate-co-adipate) (PBSA) trays (a) and paper/polyethylene terephthalate (PET) trays (b) with mean values of seal strength (N/m) and images of the bilayer separation by delamination.
Figure 9
Figure 9
Visual images with storage time of fresh pasta packaged in trays, from left to right, of: monolayer paper, bilayer paper/poly(butylene succinate) and poly(butylene succinate-co-adipate) (PBS–PBSA) blend, and bilayer paper/polyethylene terephthalate (PET). (Left pictures): trays with the packaged pasta; (Middle pictures): pasta in trays after opening; (Right pictures): unpackaged pasta.
Figure 10
Figure 10
Percentage of mass loss of unpackaged and packaged fresh pasta in trays of monolayer paper, bilayer paper/poly(butylene succinate) and poly(butylene succinate-co-adipate) (PBS–PBSA) blend, and bilayer paper/polyethylene terephthalate (PET).
Figure 11
Figure 11
Evolution of water activity (aw) of unpackaged and packaged fresh pasta in trays of monolayer paper, bilayer paper/poly(butylene succinate) and poly(butylene succinate-co-adipate) (PBS–PBSA) blend, and bilayer paper/polyethylene terephthalate (PET).
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